Method for producing a fastening system, in particular for components of photovoltaic systems

ABSTRACT

Method for producing a fastening system, in particular for components of photovoltaic systems, preferably on roof surfaces of buildings, includes providing a support surface ( 1 ) and applying at least one fastening component ( 7, 19 ) of loops and/or other interlocking elements on the support surface. After applying the fastening component ( 7, 19 ) in the mounted state of the support surface ( 1 ), at least one other corresponding fastening component ( 7, 19 ) provided with other interlocking elements can be detachably connected to the fastening components ( 7, 19 ) on the support surface.

FIELD OF INVENTION

The invention relates to a method for producing a fastening system, inparticular for components of photovoltaic systems, preferably on roofsurfaces of buildings. Furthermore, the invention relates to a fasteningsystem produced according to such a method, and to a support element anda support surface which are intended for use in such a fastening system.

BACKGROUND OF INVENTION

Fastening systems in which touch-and-close connections of complementaryinterlocking elements which can be engaged to one another are used inorder to fasten components, such as solar power components, to supportsurfaces, especially roof surfaces, are prior art; compare, for example,DE 103 29 184 A1 or WO 2011/076307 A1. In the practical use of suchsystems, the attachment of the interlocking elements to an attachmentsurface of the supporting structure, that is to say, a building surfaceor roof surface, presents no problems only in those cases in which thesurface composition of the attachment surface is suitable enough forproducing the connection to the interlocking element. In roof surfaces,this is often not the case, for example, when there are concretesurfaces, or rough wood surfaces, or insulating layers. A reliableconnection can be produced in such cases at best by using specialtouch-and-close fastener elements in which there are interlockingelements on a support which is compatible with the respective surfacecomposition of the attachment surface. In ordinary touch-and-closefastener elements with fleece-like, nonwoven-like, or fabric-likebacking, this is not the case. The necessity of special selection of thetouch-and-close fastener elements to be used and the special measureswhich must be taken for a reliable attachment of the touch-and-closefastener elements to the attachment surface lead to complication andincreased costs in the prior art.

SUMMARY OF THE INVENTION

With respect to these problems, the object of the invention is to devisea method for producing a fastening system which enables a simple,reliable, and economical fastening of the corresponding components.

This object is basically achieved according to the invention by a methodwhere a support surface is be provided and at least one fasteningcomponent of loop and/or other interlocking elements is applied on thesupport surface after fastening the respective fastening component inthe mounted state of the support surface, at least one othercorresponding fastening component provided with other interlockingelements is detachably connected to the assignable fastening components.Regardless of the respective type of the attachment surface or roofsurface, on the top of the support surface for attaching the fasteningcomponent a suitable joining surface is thus available so thattouch-and-close fastener elements of any desired structure can be easilyand reliably attached as fastening components.

Especially advantageously, the support surface can be produced from abitumen mass or from plastic, on at least one surface region of thesupport surface at least one fastening component being attached,preferably by coating or laminating it on.

When using a plastic support surface, it is preferable to proceed suchthat the support surface is provided in the form of a thin plasticsheet, preferably of an elastomer material, for example, from asynthetic rubber material or a thermoplastic olefin.

In especially advantageous exemplary embodiments, it is possible toproceed such that to form the support surface, a backing web isprovided, for example, in the form of a thin tape of a plastic, such asPET or the like, with the backing web being applied in one transportdirection at an application station on which a bitumen mass is applied,preferably by doctoring, and being moved past a following attachmentstation at which the assigned fastening component is attached in thechosen surface area.

Bitumen layers as are installed as insulating layers on buildingsurfaces or roof surfaces are often provided with an intercalated orattached granulate. When using a bitumen layer to form the supportsurface according to the method according to the invention, it ispossible to proceed in this respect such that the backing web providedwith the bitumen mass and with the fastening component is moved past asprinkling station on which a granulate is applied on the surfaceregions which are free of the fastening component.

The subject matter of the invention is also a fastening system producedusing the method according to the invention and characterized in thatthe respective fastening component can be joined to the support surfaceand is located on a support element designed as a holder for structuralelements, especially components of photovoltaic systems.

Especially advantageously, the respective support element can be made inthe form of a mounting rail which on the side facing the support surfaceis provided with the pertinent fastening component in the form of atouch-and-close fastener element. In this connection, thetouch-and-close fastener element which is located on the support surfacecan be provided in the form of at least one tape which extends on thearea of the support surface and along the respectively assigned mountingrail.

Especially advantageously, the respective mounting rail can be made inthe form of a profile of plastic, for example, anacrylic-nitrile-styrene-acrylate. This type of profile can be extrudedin an extrusion process and can be subdivided into longitudinal sectionsintended for the respective application.

Preferably, the respective profile is made as a hollow profile which hasreceiving spaces for holding lines or other components of photovoltaicsystems which are inserted into them.

Especially advantageously, the respective hollow profile can have wallparts for forming support and/or fastening regions for solar panels.

The mounting rail, especially for the attachment of flexible solarpanels, can be made in the form of a profile strip which has at leastone longitudinal slot for accommodating the fastening edge of apertinent solar panel, which edge is inserted into it.

The subject matter of the invention is also a support element for use ina fastening system according to the invention, with the support elementbeing characterized in that it is made in the form of a mounting railwhich has been extruded from a plastic material.

The subject matter of the invention is furthermore a support surfacedesigned for use in the fastening system according to the invention andcharacterized in that it is formed from a bitumen mass or in the form ofa thin plastic sheet, preferably of an elastomer material. On the top ofthe support surface there is at least one touch-and-close fastenerelement in a location which is in a positional relationship to anassigned support element which is to be fastened.

Other objects, advantages and salient features of the present inventionwill become apparent from the following detailed description, which,taken in conjunction with the annexed drawings, discloses preferredembodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial detached perspective oblique view of one supportsurface in the form of a bitumen mass with a touch-and-close fastenerelement located on it as a component of one exemplary embodiment of thefastening system according to the invention;

FIG. 2 is shows a side view of in the support surface of FIG. 1;

FIG. 3 is a perspective view of one support surface in the form of anelastomer plastic sheet with a touch-and-close fastener element locatedon it as a component of another exemplary embodiment of the fasteningsystem according to the invention;

FIG. 4 shows a section according to section line IV-IV from FIG. 3;

FIG. 5 is a perspective view of a longitudinal section of one exemplaryembodiment of a support element as a component of one exemplaryembodiment of the fastening system according to the invention;

FIG. 6 is a side elevational view in a cross section of the supportelement of FIG. 5 with the assigned touch-and-close fastener elementlocated on it;

FIG. 7 is a perspective view of a modified exemplary embodiment of asupport element according to the invention;

FIG. 8 is a side elevational view in section of the support element ofFIG. 7;

FIG. 9 is a perspective view of a support element similar to FIG. 7 withlines inserted into it according to an exemplary embodiment of theinvention;

FIG. 10 is a side elevational view in cross section of in the supportelement FIG. 9;

FIG. 11 is a perspective view of one modified exemplary embodiment ofthe support element in the form of a profile strip with solar panelsfastened on it according to the invention;

FIG. 12 is an enlarged side elevational view of the profile strip ofFIG. 11, and

FIG. 13 is a highly schematically and simplified side elevational viewof a device for producing a support surface for use in the fasteningsystem according to an exemplary embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The exemplary embodiment of a support surface 1 shown in FIGS. 1 and 2is formed by a bitumen web 2 on whose surface 5 a touch-and-closefastener element 7 is fastened. The latter extends in the form of astrip or tape 9 over the top 5 of the web 2 of bitumen mass, with thesurface region of the bitumen web 2, which is free of thetouch-and-close fastener element 7, being provided with attachedgranulate 4. The bitumen web 2, which is made to have a much larger areathan the touch-and-close fastener element 7, with its underside 11 makesavailable a correspondingly large-area connecting region for theconnection to a corresponding support surface (which is not shown), forexample, a roof surface or components thereof.

The tape 9 of the touch-and-close fastener element 7 extends in apositional orientation which is aligned to an assigned support elementwhich is to be anchored on the support surface 1. The respective supportelement 13 is a mounting rail shown in FIGS. 5 to 10 as exemplaryembodiments, or is a respective profile strip 16 as is shown in FIGS. 11and 12. In FIG. 1, on the support surface 1, there is only one tape 9 ofthe touch-and-close fastener element 7 for a single support element onthe bitumen web 2. In systems with several support elements on a commonsupport surface 1, there can be several tapes 9 with touch-and-closefastener elements 7, or there can be several support surfaces 1 with onetape 9 each, as is shown in FIG. 1.

FIGS. 3 and 4 show a second exemplary embodiment of the support surface1 in the form of a sheet 3 of an elastomer plastic material, forexample, a synthetic rubber or a thermoplastic olefin. As in theexemplary embodiment from FIGS. 1 and 2, a touch-and-close fastenerelement 7 in the form of a tape 9 on the top 5 of the support surface 1is attached by coating or laminating it on. In the example of FIGS. 1and 2, touch-and-close fastener elements which in the known constructioncan have interlocking elements 21 in the form of mushrooms, loops, orhooks. In the exemplary embodiments provided here, there areinterlocking elements 21 in the form of loops in the touch-and-closefastener elements 7 provided on the support surface 1. Thesetouch-and-close fastener elements 7 form a kind of fleece with a baseformed by a fabric. With respect to the permeability of the base, inlamination or cementing onto the top 5 of the support surface, forexample, of the bitumen web 2, the procedure is such that there is nomaterial passage through the base, for example, by plasticized bitumen,to the region of the interlocking elements 21 in the form of loops.

FIGS. 5 and 6 show a first exemplary embodiment of a mounting rail 13 inthe form of a hollow profile 15, which is extruded from a plasticmaterial in an extrusion process. It can be a thermoplastic polymer, forexample, acrylic-nitrile-butadiene-styrene (ABS) or preferably anacrylic-nitrile-styrene acrylate. In order to protect parts of thehollow profile 15 which are exposed during use, there can be a sunproofand/or weather-resistant coating at least on outside surfaces of thehollow profile 15. For example, materials such as polymethylmethacrylate(PMMA) or polytetrafluorethylene (PTFE) are suitable for this coating.This coating can be efficiently formed by a coextrusion method in theproduction of the hollow profile 15.

The hollow profiles 15 on the underside have a flat fastening surface 17for attaching a touch-and-close fastener element 19 which corresponds tothe touch-and-close fastener element 7 of the support surface 1. Likethis touch-and-close fastener element 7, the touch-and-close fastenerelement 19 also has interlocking elements 21 on a backing 23 which onthe side of the support surface 1 cements or bonds to the top 5 of thesupport surface 1 or is laminated onto it and on the side of the hollowprofile 15 is cemented or bonded to the fastening surface 17. Thetouch-and-close fastener elements 7 and 19 can be made in a conventionalmanner, i.e., they can have conventional interlocking elements 21 in theform of mushrooms, loops, or hooks. In the present exemplary embodiment,the interlocking elements 21 are made on the hollow profile 15 in theform of mushrooms.

Instead of the example which is shown in FIG. 6 and in which thetouch-and-close fastener element 19 with its backing 23 is fastened onthe fastening surface 17, alternatively, the interlocking elements 21,especially in a version as mushrooms, can also be formed on thefastening surface 17 of the material of the hollow profile 15 itself. Onthe two end edges of the fastening surface 17 as an edge enclosure, aslightly projecting edge rib 25 is formed as a lateral guide for therespective tape of the touch-and-close fastener element 19 which islocated on the fastening surface 17. The hollow profile 15 has,proceeding from the lower fastening surface 17, flat side walls 27 whichrun slightly converging upward and on the upper end undergo transitioninto profile webs 29 which extend opposite one another in the planeparallel to the fastening surface 17, but end at a distance from oneanother. Within the profile shape, inner walls 31 are formed whichextend proceeding from the central region of the fastening surface 17diverging to one another upward toward the profile webs 29 and with theside walls 27 border one receiving space 33 at a time. An intermediatewall 35 which runs in a parallel plane underneath the profile webs 29between the inside walls 31 borders another triangular space 37 and anoverlying space 39 which is open between the profile legs. The flatoutside surfaces of the profile legs 29 and the space 39 which forms atype of dovetail guide form a support and attachment region for apertinent component which is to be fastened (which is not shown), and itcan be, for example, a component of a solar power system, for example, asolar panel.

FIGS. 5 and 6 show one exemplary embodiment of the hollow profile inwhich an overhanging rail 41 is molded on one side wall 27 and forms anopen receiving space 43 which can be used, for example, as a cable ductfor lines 45 (FIGS. 9 and 10).

FIGS. 7 and 8 show a modified exemplary embodiment of the hollow profile15 which differs from the example from FIGS. 5 and 6 simply in that theinside walls 31 run at a distance to one another, parallel to oneanother, and perpendicular to the fastening surface 17, so that space 43located underneath the intermediate wall 35 has a rectangular crosssection.

FIGS. 9 and 10 show one modified exemplary embodiment of the hollowprofile 15 from FIGS. 7 and 8 without the laterally attached rail, withone line 45 at a time being inserted into the receiving spaces 33 formedbetween the side wall 27 and inside wall 31. The hollow profile fromFIGS. 9 and 10 and likewise the hollow profile 15 from FIGS. 7 and 8also differ from the hollow profile 15 according to FIGS. 5 and 6 inthat the space 39 open at the top has the cross-sectional shape of arectangular dovetail guide with wall parts which run perpendicular toone another by the end sections of 47 of the inside walls 31, whichsections run parallel to one another.

FIGS. 11 and 12 show one modified embodiment for the mounting rail 13 inthe form of an elongated, relatively flat profile strip 16. In the samemanner as the hollow profile 15, the profile strip is extruded from acorresponding plastic material in an extrusion process. The strip 16,like the hollow profile 15, on the underside has a flat fasteningsurface 17 for a touch-and-close fastener element 19. In the centralregion of the fastening surface 17, from its top 18 a clamping part 20extends in the longitudinal direction of the strip 16, with the clampingpart 20 having a cross-sectional shape in the form of a flat T withlateral clamping wings 22 which border a longitudinal slot 24 betweenthemselves and the top 18 of the fastening surface 17. As FIG. 11illustrates, a flexible solar panel 26 can be inserted into therespective longitudinal slot 24, with the wings 22 fastening thefastening edge 28 of the solar panel 26 by clamping; see FIG. 11. Thesolar panel 26 can be an arrangement of solar modules which is locatedon a backing film which consists of a preferably napped plastic sheetwith a rectangular outline. In commercial solar panels of this type, theplastic film supporting the modules has dimensions of about 55×40 cm andconsists of a weather-resistant plastic material, such as PMMA or PTFE,with the edge zones 28 which are free of modules being usable as holdingregions for fastening of the panels 26.

FIG. 13 shows highly simplified the production of a support surface 1 ona bitumen web 2 which is provided with the assigned touch-and-closefastener element 7 and with attached granulate 4. In the device, abacking web 30 of plastic material such as PTFE is moved in onetransport direction marked with arrow 32 past an application station 34on which a bitumen layer 40 is formed on the transport web 30 from abitumen mass, a so-called “molasses” 36, by means of a doctor blade 38.The transport web with the formed bitumen layer 40 is moved past anattachment station 42 at which the pertinent touch-and-close fastenerelement 7 is attached on the top of the bitumen layer 40; as describedabove, this takes place by cementing it or laminating it on. Then thetransport web 30 with the bitumen layer 40 and with the attached tape ofthe touch-and-close fastener element 7 runs through a drier 44 to afollowing sprinkling station 46 at which granulate for attachment isscattered in the surface regions which are free of the touch-and-closefastener element 7. The support surface 1 which has been produced inthis way can at this point be wound up together with the backing web 30and transported as a coil to the site of use (such as a constructionsite) where, after unwinding, the backing web 30 can be removed from theunderside of the support surface 1 before its actual use.

One very great advantage of this invention is that in the indicatedproduction method, the loop tape to be applied with its base fabricstructure need not be immersed into the bitumen web, but is appliedrather almost flush to the top of the bitumen web. If bitumen componentspenetrate into the base surface of the backing fabric of the loop tape,they allow a strong connection of the loop tape to the base backingmaterial in the form of the bitumen layer without the interlockingcapacity of the loop material being adversely affected. This alsoapplies to the case in which the loop surface is replaced by aninterlocking layer also in a mushroom form.

While various embodiments have been chosen to illustrate the invention,it will be understood by those skilled in the art that various changesand modifications can be made therein without departing from the scopeof the invention as defined in the appended claims

What is claimed is:
 1. A method for producing a fastening system onbuilding roof surfaces for photovoltaic systems, comprising the stepsof: providing a support surface, the support surface being formed byproviding a backing web, conveying the backing web in one transportdirection to an application station where a bitumenous mass is appliedto the backing web by doctoring, and conveying the backing member withthe bitumen mass to a location at which at least one first fasteningcomponent is applied; applying the first fastening component of at leastone of loops and other interlocking elements of a touch-and-closefastener on the support surface; and detachably attaching a structuralelement holder having at least one second fastening component of atleast one of loops and other interlocking elements of a touch-and-closefastener matable with and on the first fastening component in a mountedstate of the support surface.
 2. A method according to claim 1 whereinthe first fastening component is attached on the support surface by oneof coating and laminating.
 3. A method according to claim 2 wherein thebacking web is an elastomeric thin plastic sheet.
 4. A method accordingto claim 1 wherein the backing web with the bitumenous mass and thefirst fastening component is moved past a sprinkling station applying agranulate to surface regions of the backing web free of the firstfastening component.